Spacing member of relatively stiff sheet-like material



Nov. 2, 1965 R. L. TECHMAN SPACING MEMBER OF RELATIVELY STIFF SHEET-LIKE MATERIAL 2 Sheets-Sheet 1 Filed Aug. 16, 1963 IOI IN VENTOR.

FIG. 1

FIG. 1o.

RICHARD LTEGH MAN BY Z % fizi ATTORN EYS Nov. 2, 1965 R. L. TECHMAN 3,215,331

SPAGING MEMBER OF RELATIVELY STIFF SHEET-LIKE MATERIAL Filed Aug. 16, 1965 2 Sheets-Sheet 2 FIG. 4

INVENTOR. "R'IQHAR L.TECH MAN A'TTORNEVS United States Patent 3,215,331 SPACING MEMBER OF RELATIVELY STIFF SHEET-LIKE MATERIAL Richard L. Techman, Whittier, Califi, assignor to Owens- Illinois Glass Company, a corporation of Ohio Filed Aug. 16, 1963, Ser. No. 302,589 11 Claims. (Cl. 229-44) The present invention relates generally to the art of packaging and more particularly to the field of package construction using relatively stiff sheet-like material, such as corrugated board, fiberboard and the like. Even more particularly, the present invention relates to the design and construction of novel blanks which, by reason of their construction, are ideally adapted to formation into multiple layer, yet integral, cushioning elements for isolating packaged products within a shipping container so that the jostling and shifting attendant shipping will not damage the element contained in the package involved.

Heavy duty fiberboard and corrugated board are ideally utilized as a packaging envelope or receptacle for a variety of products in view of the low cost and ready formability into a variety of contours. Furthermore, it is usually advantageous to form various cushioning packs and isolation members of heavy duty fiberboard or corrugated board in order to further protect the article or item contained in the receptacle or shipping container. It is, of course, known that fiberboard and corrugated board can be manufactured economically to only a given thickness. Thus, conventional corrugated board formed of two sheets of kraft having sandwiched therebetween a fluted or convoluted sheet of corrugating medium are known. Additionally, double wall corrugating board and even triple wall corrugating board has been manufactured. In double wall and triple wall, a plurality of facing or linner sheets are used and two or three fluted or convoluted arrangements of corrugating medium are embraced thereby to form the double or triple wall board. In order to increase the cushioning of double wall board, it has been proposed that sandwiches of these materials or sheets be formed to provide still further cushioning against forces normal to the cushioning board so erected. Merely utilizing a plurality of layers of a corrugated board is not a satisfactory solution to the problem of providing additional cushioning, since the mere use of a plurality of sheets of corrugated board involves independent pieces of board which, if they must accommodate protuberances on the article being packed, must be die cut and indexed, thereby making packaging of the article by the manufacturer quite difficult. Built up pads of several individual sheets of corrugated board have been produced by gluing the sheets together in face to face relationship. This, however, involves additional operations and is not completely satisfactory.

Attempts have also been made to form a conventional corrugated board blank which is foldable into a multiple layer-pack of utility in end cushioning of a variety of products. Techniques have been developed whereby a multiple layer or multiple ply board is passed beneath slotting and die cutting equipment several times in sequence to provide a specially designed blank which is capable of being so folded into a somewhat smaller end cushioning pack. Unfortunately, multiple passes at conventional slotting and die cutting machinery greatly increases the cost to the point that it is non-competitive with other forms of packaging.

Accordingly, it is an object of the present invention to provide a blank formed of relatively stiff sheet-like material, which blank is so slitted, scored and slotted that it is capable of relative foldability into a compact pad-like structure of integral strength in all directions and, there- 3,215,331 Patented Nov. 2 1965 fore, capable of satisfactorily providing end packing strength in a receptacle formed of relatively inexpensive sheet-like material, e.g., paperboard, corrugated board and the like.

It is also an object of the present invention to provide a blank formed of relatively stiff sheet-like material which can be produced in accordance with the present invention with a single pass through conventional die-cut equipment.

It is still another object of the present invention to provide a blank of multiple-ply thickness of paperboard, which blank is relatively easily produced without the necessity of several passes through conventional die cutting and slitting apparatus.

It is a particular object of the present invention to provide a novel die cutting and slitting technique which envisions a particular combination and configuration providing relative foldability of a plurality of semi-connected panels so arranged as to yield, as an end result, a multiple layer-pack.

It is yet another object of the present invention to provide an end cushioning pack formed of relatively inexpensive multiple-ply paperboard material, which pack is of integral construction, that is, of single piece construction and, therefore, possessed of greater strength than a plurality of independent sheets used as an end packing member.

The foregoing and other objects of the present invention will become apparent to those skilled in the art from the following detailed description taken in conjunction with the annexed sheets of drawings on which there is presented, for purposes of illustration only, several embodiments of the present invention.

In the drawings:

FIG. 1 is a plan view of a corrugated board blank having a configuration and design in accordance with the preferred embodiment of the present invention.

FIG. 1a is likewise a plan view of a blank formed of paperboard and in accordance with a related embodiment of the present invention.

FIG. 1b is an enlarged view of the portion of the blank shown encircle in FIG. 1.

FIG. 2 is a partial edge view taken from the line 22 of FIG. 1.

FIG. 3 is a partial edge view taken from the line 33 of FIG. 1.

FIG. 4 is a partial edge view taken from the line 4-4 of FIG. 111.

FIG. 5 is a perspective view of the blank shown in FIG. 1, but illustrating the relative position of the panels forming the blank at an intermediate stage of the folding of the blank into the ultimate unitary multiple thickness pack or pad.

FIG. 6 is a perspective view, like FIG. 5, showing the relative positions of the panels making up the blank shown in FIG. 1 and a yet later sequence or stage of the formation of the blank into the ultimate unitary end pack or end ad. P FIG. 7 is a perspective view, mostly broken away, of a bridging or hinging element connecting the foldable cut and score defined panels constituting the blank in accordance with the present invention.

FIG. 8 is a perspective view of the ultimate, unitary end cushioning pack or pad in accordance with the present invention, shown partially in preliminary assembled relationship with an outer wrap and an article, in this case, a hot water heater, ready to be packed for shipping by the manufacturer.

In its simplest embodiment, the present invention envisions a blank formed of relatively stiff sheet-like material which is so configurated of cuts and scores as to define a plurality of panels which are connected together by cut scores, complete cuts, partial cuts and scores as to lend a unique relative foldability of the individual panels so as to yield a unitary multiple thickness pad from the single blank as described. The present invention envisions a unique combination of the steps of die cuttlng and die scoring a multiple-ply blank of paperboard as to be easily erectable by the user into a multi-ply cushioning member of particular utility in packaging relatively heavy appliances, such as water heaters, within relatively inexpensive receptacles formed, for example, of corrugated board, fiberboard and the like.

Referring now more specifically to the drawings, there is disclosed in FIG. 1 a blank 11 which is of generally square configuration having parallel upper and lower edges 12 and 13, respectively, and parallel side edges 14 and 15, respectively. The blank is formed of double wall corrugated board, in which the corrugations in each wall extend linearly as shown in the cut-away corner, e.g., parallel to side edges 14 and 15. Double wall corrugated board is well known in the art and need not be described as to its manufacture except to say that it is made up of an upper facing liner sheet 17, a middle liner sheet 18 and a lower facing liner sheet 19 (see FIG. 3). Sandwiched adhesively between the parallel-spaced sheets 17 and 18 is a fluted corrugating medium 20, while the parallelspaced sheets 18 and 19 have a fiuted corrugating medium 21 adhesively sandwiched therebetween. The blank 11 includes generally corner panels 23, 24, 25 and 26. The just mentioned panels are separated from each other by full thickness cuts 27 and 27a which are normally disposed and extend between the outer edge pairs 14,15 and 12, 13, respectively, excepting for a plurality of identical bridging portions 30 and 31. The cuts 27 and 27; extend all the way through the thickness of the double wall board. The cuts 27 and 27a intersect proximately in the center C which is a point common to the panels 23-26.

The bridging portions or hinges 30 and 31 are each composed of a pair of short full thickness cuts 32 and 33 in parallel-spaced relationship intersecting with cuts 27 or 27a; the end extremities of which cuts 32 and 33 are connected by parallel score lines 34 and 34a on either side of the blank (see FIGS. 1 and 4).

Generally square panels 23 and 25 are further provided with partial thickness cuts or slit scores 36 and 3611; cut 36 extending from corner 37 to the center C, while cut 36a extends from the center C to corner 38, the latter being cut away for a purpose to be explained. The cut 36 extends through the liner sheet 17, corrugating medium 20, liner sheet 18 and corrugating medium 29, leaving undisturbed the lowermost liner sheet 19 which serves as a hinge. Details of the full thickness cuts, partial cuts, scores, etc., are shown in more detail in FIGS. 1b, 2, 3 and 4. The diagonal cut 36 .divides panel 23 into triangular segments 23a and 23b and panel 25 into triangular segments 25a and 25b. Each of the panels 23-26 is additionally provided with die cutouts which in the erected article provide locating aparatures for the packaged article.

The cutouts 50 are located in such a way that they will assume registration in the ultimately folded over pad as will be described. The panels 23, 24, 25 and 26 are not exactly equal in size, it will be appreciated, since the thickness of the blank and the multiple folding necessitate some adjustment in the placing of the cuts and scores in order to achieve an ultimate pad which is composed of layers having overlying edges in registry.

The blank 11, slotted, cut and scored as described in FIGS. 1, 2 and 3, is thereby adapted for unique self-fold ability into a multiple-ply construction composed of four thicknesses of double wall board. The folding is illustrated, for example, in FIGS. 5 and 6. Using panel 24 as a base reference, one assembles the blank by grasping the triangular panels 23b and 25b withleft and right hands, respectively, and lifts it upwardly whereby the blank folds about the diagonal lines 36 and 36a, while panel 26 moves upwardly out of its planar relationship. As the folding continues, the partially cut fold line 36 separating panels 23a and 23b and fold line 36a separating panels 25a and 25b approach each other as shown in FIG. 6, while the triangular segments 23a and 23b, as well as 25a and 25b, assume reverse folding relationship with each other to form two thicknesses of the total of thickness pad. In addition, the panel 26 connected to each of the triangular panels 23a and 25a by the bridging portions 30 and 31, respectively, assumes generally flush relationship with the triangular panels 23a and 25a, while the triangular panels 23b and 25b have assumed flush relationship with the base panel 24 to which they are connected by bridging portions 31 and 30, respectively. FIG. 7 discloses a rear view of a single bridging portion 30 connecting panels 25b and 24 and illustrates the cooperative interaction of the cuts 32 and 33 and scores 34 and 34a in yielding a hinging action between two panels. A similar effect obtains at all the bridging portions, although the corrugations will appear different from those in FIG. 7 depending upon which panels are, in elfect, bridged together. Cut or notched corner 38 forms an edge When folded over into overlying relationship with edge 13 (FIG. 6). It is a unique feature of the construction herein provided that the combination of the full cuts 27 and 27a and partial thickness cuts 36 and 36a in the same multiply blank provide foldability of the defined panels in one direction and also in the reverse direction, e.g., the panels 24 and 23b illustrate folding in the one direction, while the panels 23a and 23b illustrate 180 reverse foldability.

The fully folded pack 60 is shown in FIG. 8 as a top spacer unit having die-cut holes 61, 62 and 63 formed by the registering relationship of the cutouts 50 contained in the panels 23 through 26, as described hereinbefore. These die-cut registering holes are adapted to receive the flue 71 and the water pipes on either side (but not shown) extending from the hot water heater (shown in dotted outline) positioned beneath the end pack 60. The heater and end pack are shown in FIG. 8 ready to be enveloped by a receptacle blank composed of connected rectangular panels 91, 92, 93 and 94, each of which contains foldably connected full closure flaps 91a, 92a, 93a and 94a, respectively. Panel 94 includes a side flap 94b which is adapted to fold over side panel 91 and be stitched or glued to complete the tube-like receptacle embracing the pack 60 and the water heater 80. The end closure flaps 91a through 94a are then folded over into abutting contact with the pack 60 for stitching, stapling, gluing or the like. It will be appreciated that a pad or pack similar to the pad 60 illustrated may be used at the other end of the re ceptacle, although such is not shown in the drawings in the interest of simplicity of illustration.

FIG. 1a discloses a blank embodying a related but simpler embodiment. This blank 101 is likewise formed of double wall corrugated board, such as is illustrated in FIG. 2 in section. The blank, however, is formed of generally square connected panels 103, 104 and 102. Panels -103 and 104 are side by side, while panel 102 is situated above panel 104. Panels 103 and 104 are separated by a full depth cut 105 extending from the lower edge 106 to a bridging portion 107 and thence extending to a bridging portion 108, continuing on to the center C which represents the common intersection point of the panels 103 through 105. An identical full depth cut 105 separates panels 104 from 102, leaving bridging portions 107 and 108. The bridging portions 107 and 108 are identical to bridging portions 30 and 31 and their make-up will not be repeated. Panels 103 and 102 are provided with partial depth cuts 110 and 111, respectively, which divides the panel 103 into triangular segments 103a and 103b and, at the same time, divides panel 102 intotriangular segments 102a and 102b, respectively. Partial cuts 110 and 111 are identical to cuts 36 and 36a in the blank 11. The blank 101, as just described, is assembled or folded into its final form in exactly the same manner as the blank 11 as illustrated in FIGS. 5 and 6. One need simply grasp the panels 103b and 1112b and lift upwardly to cause a folding of the triangular segments about the partial depth cut score 105, whereupon the panels 103a and 102a will fold reversely about the partial cuts 110 and 111, respectively. The erection of the blank will proceed in the same manner as disclosed in FIGS. 5 and 6 with the exception that the panel 26 is not present so that the ultimate pad is composed of three thicknesses of double wall board instead of four, as in the blank 11.

The ultimately formed unitary multiple thickness pack or pad as described herein is easily erectable by the ultimate consumer from the blank 11 or blank 101. In its folded over configuration, as shown in FIGS. 7 and 8, the pad, as identified by reference numeral 60, is eminently desirable as an isolation or spacing member as Well as a cushioning aid since it is formed of one piece and, therefore, of unusual rigidity and structural integrity. Additionally, by reason of the particular arrangement of the cuts (full and partial) and the accompanying folding features, the corrugations in some of the thicknesses run in one direction, while the corrugations in the remaining thicknesses run in a direction normal thereto. The blank 11 will yield a pad in which, of the four thicknesses, two will have corrugations in one direction and two will have corrugations normal thereto. The strength of corrugated board is greatest in the direction of the corrugations. Therefore, the ultimate pad as constructed from the blank -11 has equal resistance to compressive forces applied to any of the four sides whereby the ultimate product, such as the hot water heater 80, is protected against lateral displacement as well as from axial or end forces.

The corrugated board and the blank as described herein have been illustrated as formed of double-Wall corrugated board. It will be appreciated that the construction of the present invention may well be employed with a variety of other packaging materials formed of a ply up of layers of relatively stiff sheet-like material. The essence of the invention resides in the combination of the several means of delineating the separation line between connected panels, constituting, in planar array, a blank. The invention resides in the fact that the blank may be conveniently formed by the manufacturer of the corrugating or corrugated board and this corrugated board, for example, double-wall corrugated board, passed just once through a conventional slit-scoring apparatus set up to impart, to the blank, the scores, slots, full depth cuts, partial depth cuts, etc., as described herein, whereupon without any further or additional treatment, the blank, e.g., 11 or 101, may be stacked and/or bound together on a pallet and shipped to the ultimate consumer. The consumer need simply self fold the blank in a manner as described into an integral multi-layer pad which is possessed of uniform resistance to compression from all edges and, as well, from the top or bottom. It will be appreciated that pads such as described may be used both at the top and .bottom of appliances and other heavy units and/or equipment.

Modifications may be resorted to without departing from the spirit and scope of the invention as defined in the appended claims.

I claim:

1. A blank formed of multiple-ply, relatively stiff sheet material, said blank including side by side panels separated by a linear full thickness cut interrupted by a bridging portion composed of (a) two minor full thickness cuts normal to and connecting with said first mentioned cut and (b) parallel scores connecting the extremities of said minor slits, said blank including a third panel connected to one of said side by side panels and separated by a linear cut extending only partially through the total thickness of said sheet material.

2. A blank as claimed in claim 1, having three connected panels separated by a full thickness cut interrupted by a bridging portion as defined in claim 1, said blank including a fourth and fifth panel connected respectively to the outermost two of said first mentioned three, said fourth and fifth panel being separated from their adjoining panel by a linear cut extending only partially through the total thickness of said sheet material, said blank being foldable with the two outer of the three assuming together flush relationship with the centermost panel, and the fourth and fifth being reversely foldable with respect to said outer two into reverse flush relationship respectively with the outermost two of said three, thereby producing a three-thickness pad.

3. A planar blank of multiple-ply, relatively stifi sheetlike material, said blank being foldable into a pad of multiple thicknesses of said material and of less planar area than said original blank, said blank being composed of a plurality of foldably connected panels, certain ones of said panels being separated by a full thickness cut coextensive with said panels, excepting an uncut bridge portion connecting said panels, and certain others of said panels being separated by a partial thickness cut extending substantially the length of the margin between said panels, said partial cut extending incompletely through said material but sufiiciently that the adjoining panels can be fully folded about said unservered portion of said partial thickness cut, said bridge portion including (a) two minor full thickness cuts normal to and connecting with said full thickness cut and (b) parallel scores connecting the extremities of said minor full thickness cuts.

4. A blank as claimed in claim 3, wherein said full thickness cuts as defined therein and partial thickness cuts all intersect at a common center and are arranged in alternate relationship to define panels extending radially from said center.

5. A blank as claimed in claim 4, wherein said full thickness cuts are apart, and said partial thickness cuts are disposed and located to bisect the angle between two of said full thickness cuts, said blank having sides defining generally a rectangle of which the partial thickness cut constitutes the proximate diagonal, whereby there is defined two pairs of adjoining triangular panels lying in diametric quadrants with respect to said center and two rectangular panels in the other two quadrants, each of said triangular panels being reversely foldable about their common hypotenuse into back to back relationship, while said faces of said triangular panels assume face to face flush relationship with said rectangular panels.

6. A blank of relatively stiff sheet-like material, said blank being foldable into a cushioning pad composed of a plurality of thicknesses of said material, said blank including four proximately sized, generally square, panels having a common corner generally proximate the center of said blank, said panels each being separated from the adjacent panel by a full thickness cut extending incompletely of the line separating said panels, leaving at least one uncut bridging portion, two of said panels having diametric corners connected by a partial thickness cut extending diagonally substantially across both panels and through the general center of said blank, said panels, by

reason of said construction, being foldable on said full thickness cut lines, scores and partial thickness cut lines into a pad composed of four thicknesses of said material.

7. A blank of multiple-ply, relatively stifi sheet-like material, said blank being foldable into a cushioning pad composed of a plurality of thicknesses of said material, said blank being generally square in plan outline, said blank including four proximately sized, generally square, panels having a common corner generally proximate the center of said blank, said panels each being separated from the adjacent panel by a full thickness cut extending incompletely of the line separating said panels, leaving at least one uncut bridging portion, said portion including spaced parallel score lines lending foldability to said panels on the said line, two of said panels having diametric corners connected by a partial thickness cut extending diagonally substantially across both panels and :through the general center of said blank, said partial thickness cut and said score being on the same face of said blank, said panels, by reason of said construction, being foldable on said full thickness cut lines, scores and partial thickness cut lines into a pad composed of four thicknesses of said material.

8. A cushioning pad formed of a plurality of connected panels folded over into overlapping relationship,

said panels including a first panel and a second panel separated by a full thickness cut extending incompletely of the line separating said first and second panels to thereby define a bridging portion connecting said first and second panels, said pad including a third panel connected to said second panel and separated therefrom by a partial thickness cut extending substantially the entire length of the line separating said panels, said second and third panels being of triangular configuration with a common hypotenuse defined by the partial thickness cut.

9. A cushioning pad as claimed in claim 8 which includes fourth and fifth panels like the said second and third panels but connected to another side of said first panel.

10. A cushioning pad as claimed in claim 8 which includes a fourth panel and a fifth panel of triangular configuration similar to said second and third panels, said fourth panel being connected to the first mentioned panel and separated by a full thickness cut extending incompletely of the line separating said panels to thereby define a bridging portion connecting said first and fourth panels.

11. A planar blank of multiple-ply, relatively stiff sheetlike material, said blank being foldable into a pad of multiple thicknesses of said material and of less planar area than said original blank, said blank being composed of a plurality of foldably connected panels, certain ones of said panels being separated by a full thickness cm coextensive with said panels, excepting an uncut bridge portion connecting said panels, and certain others of said panels being separated by a partial thickness cut extending substantially the length of the margin between said panels, said partial cut extending incompletely through said material but sufiiciently that the adjoining panels can be fully folded about said unsevered portion of said partial thickness cut, said full thickness cuts and partial thickness cuts all intersecting in a common center and being arranged in alternate relationship to define panels extending radially from said center, said full thickness cuts being located apart and said partial thickness cuts being disposed and located to bisect the angle between two of said full thickness cuts, said blank having sides defining generally a rectangle of which the partial thickness cut constitutes the proximate diagonal, whereby there is defined two pairs of adjoining triangular panels lying in diametric quadrants with respect to said center and two generally rectangular panels in the other two quadrants, each of said triangular panels being reversely foldable about their common hypotenuse into back-to-back relationship, while said faces of said triangular panels assume face-to-face flush relationship with said rectangular panels.

References Cited by the Examiner UNITED STATES PATENTS 1,380,880 6/21 Austin 22941 1,844,468 2/32 Fischer 206-57 2,805,810 9/57 Butz 229--14 2,932,438 4/60 Smith 22914 2,978,163 4/61 Anderson 229-14 JOSEPH R. LECLAIR, Primary Examiner.

FRANKLIN T. GARRETT, Examiner. 

1. A BLANK FORMED OF MULTIPLE-PLY, RELATIVELY STIFF SHEET MATERIAL, SAID BLANK INCLUDING SIDE BY SIDE PANELS SEPARATED BY A LINEAR FULL THICKNESS CUT INTERRUPTED BY A BRIDGING PORTION COMPOSED OF (A) TWO MINOR FULL THICKNESS CUTS NORMAL TO AND CONNECTING WITH SAID FIRST MENTIONED CUT AND (B) PARALLEL SCORES CONNECTING THE EXTREMITIES OF SAID MINOR SLITS, SAID BLANK INCLUDING A THIRD PANEL CONNECTED TO ONE OF SAID SIDE BY SIDE PANELS AND SEPARATED BY A LINEAR CUT EXTENDING ONLY PARTIALLY THROUGH THE TOTAL THICKNESS OF SAID SHEET MATERIAL. 